Seam locking apparatus

ABSTRACT

A locking apparatus for securing a turning vane to a duct rail is disclosed. The locking apparatus includes an elongate body defining a longitudinal axis and a working end including a first end portion, a second end portion, and an arcuate portion extending between the first end portion and the second end portion. The first end portion, second end portion, and arcuate portion together define a concavity that is configured for the reception of a portion of the turning vane therein. The arcuate portion is configured for engagement against the portion of the turning vane to roll the portion of the turning vane over a portion of the duct rail. The rolling of the portion of the turning vane over the portion of the duct rail is configured to secure the turning vane to the duct rail.

FIELD

The present disclosure relates to apparatus and methods for joining and locking two pieces of sheet metal together with a mechanical seam.

BACKGROUND

Seams are used in the ductwork of HVAC systems to join sheet metal panels together. In a Pittsburgh seam, a portion of a first sheet metal panel is folded over to form a pocket for receiving a flange of a second sheet metal panel. Once the flange is inserted into the pocket, a second portion of the first sheet metal panel is bent over the flange and pocket to lock the flange in the pocket. In this manner a seam is formed between the first and second sheet metal panels that inhibits separation of the first and second sheet metal panels. Often the second portion is bent over the flange and pocket using a common hand tool such as a hammer. For example, a person forming the seam may use the hammer to bend a portion of the seam at a time. This process may be both labor and time intensive, reducing the efficiency of the process of locking the seam.

BRIEF SUMMARY

In an aspect, a system, apparatus, and method described herein for joining a first sheet metal panel to a second sheet metal panel through a mechanical seam, for example, by applying a pneumatic air hammer to a locking apparatus while sliding the locking apparatus along a flange of the first sheet metal panel. The locking apparatus powered by the pneumatic air hammer quickly and securely locks the first sheet metal panel to the second sheet metal panel by bending the flange of the first sheet metal panel over a flange of the second sheet metal panel that is inserted into a pocket of the first sheet metal panel.

In an aspect of the present disclosure, a locking apparatus for securing a first sheet metal panel to a second sheet metal panel is disclosed. The locking apparatus includes an elongate body, a proximal portion extending proximally from the elongate body and configured for removable attachment to a pneumatic air hammer, and a distal portion extending distally from the elongate body. The distal portion includes a forming surface that is configured to engage against a flange of the first sheet metal panel. The forming surface is configured to bend the flange of the first sheet metal panel over a pocket of the first sheet metal panel when the pneumatic air hammer is activated to inhibit removal of a flange of the second sheet metal panel from the pocket. The distal portion further includes a guide surface that is configured to engage against a surface of the first sheet metal panel to guide the forming surface along the flange of the first sheet metal panel.

In some aspects, the forming surface includes an arcuate portion.

In another aspect, the elongate body may define a longitudinal axis. The forming surface may include a planar portion defining a plane perpendicular to the longitudinal axis. The arcuate portion may extend from the planar portion.

In yet another aspect, a width of the planar portion may be less than a width of the arcuate portion in a direction perpendicular to the longitudinal axis and parallel to the guide surface.

In another aspect, the arcuate portion may curve proximally away from the planar portion. A radius of curvature of the arcuate portion may be defined from a point on the longitudinal axis proximal of the planar portion.

In some aspects, the guide surface may extend distally beyond the forming surface.

In another aspect, the guide surface is a planar surface.

In yet another aspect, the guide surface may be orthogonal to at least a portion of the forming surface and parallel to a longitudinal axis defined by the elongate body.

In another aspect, a fillet may be defined between the guide surface and at least a portion of the forming surface.

In other aspects, the guide surface and the forming surface may be integrally formed.

In an aspect, a method for securing a first sheet metal panel to a second sheet metal panel is disclosed. The method includes inserting a flange of the second sheet metal panel into a pocket of the first sheet metal panel, positioning a locking apparatus against the first sheet metal panel such that a forming surface of the locking apparatus engages against a flange of the first sheet metal panel and a guide surface of the locking apparatus engages against a surface of the first sheet metal panel, driving the locking apparatus against the first sheet metal panel such that the forming surface engages the flange of the first sheet metal panel and bends the flange of the first sheet metal panel over the flange of the second sheet metal panel. The bending of the flange of the first sheet metal panel over the flange of the second sheet metal panel inhibits removal of the flange of the second sheet metal panel from the pocket.

In some aspects, driving the locking apparatus against the first sheet metal panel includes sliding the locking apparatus along the flange of the first sheet metal panel from a first portion to a second portion of the flange. The sliding may be guided by the engagement of the guide surface against the surface of the first sheet metal panel. The second portion of the flange of the first sheet metal panel may be bent as the locking apparatus slides along the flange from the first portion to the second portion of the flange of the first sheet metal panel.

In another aspect, the forming surface includes at least one arcuate portion. The sliding of the locking apparatus may include engaging the at least one arcuate portion against the second portion of the flange of the first sheet metal panel.

In some aspects, a proximal portion of the locking apparatus is configured for removable attachment to a pneumatic air hammer.

In yet another aspect, the locking apparatus is translatable relative to the pneumatic air hammer between a first position and a second position when removably attached to the pneumatic air hammer. The locking apparatus may extend farther from the pneumatic air hammer when in the first positions than when in the second position. The positioning the locking apparatus against the first sheet metal panel further including positioning the locking apparatus against the flange of the first sheet metal panel with the locking apparatus in the first position and translating the locking apparatus to at least the second position while positioned against the flange of the first sheet metal panel prior to driving the locking apparatus against the first sheet metal panel.

In another aspect, driving the locking apparatus against the first sheet metal panel includes activating the pneumatic air hammer to drive the locking apparatus against the first sheet metal panel.

In some aspects, the guide surface is a planar surface.

In yet another aspect, the guide surface is orthogonal to at least a portion of the forming surface and parallel to a longitudinal axis defined by the locking apparatus.

In another aspect, a fillet is defined between the guide surface and at least a portion of the forming surface.

In some aspects, the guide surface and the forming surface are integrally formed.

Any of the above aspects may be combined in any manner without departing from the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of the present disclosure, both as to its structure and operation, can best be understood by referring to the accompanying drawings, in which like reference numbers and designations refer to like elements.

FIGS. 1A and 1B illustrate images of a locking system in accordance with some aspects of the present disclosure.

FIG. 2 is a front view of a locking apparatus of the system of FIG. 1.

FIG. 3 is a side view of the locking apparatus of FIG. 2.

FIG. 4 is a top view of the locking apparatus of FIG. 2.

FIG. 5 is an isometric view of the locking apparatus of FIG. 2.

FIG. 6 is an image of first and second sheet panels in accordance with an aspect of the present disclosure.

FIG. 7 is another image of first and second sheet panels in accordance with an aspect of the present disclosure, taken from a different angle.

FIGS. 8 and 9 are images of the first and second sheet panels of FIG. 6 with the locking apparatus of FIG. 2 positioned against a flange of the first sheet panel while in the first position relative to the pneumatic air hammer, taken from different angles.

FIGS. 10 and 11 are images of the first and second sheet panels of FIG. 6 with the locking apparatus of FIG. 2 positioned against a flange of the first sheet panel while in the second position relative to the pneumatic air hammer, taken from different angles.

FIGS. 12 and 13 are images of the first and second sheet panels of FIG. 6 with the locking apparatus of FIG. 2 sliding along the flange of the first sheet panel to bend the flange over the pockets and flange of the second sheet panel, taken from different angles.

DETAILED DESCRIPTION

With reference now to FIGS. 1A and 1B, a sheet metal seam locking system 100 is illustrated including a locking apparatus 110 and a pneumatic air hammer 150.

With reference to FIGS. 1A, 1B, and 2-5, locking apparatus 110 includes an elongate body 112 having a proximal portion 120 and a distal portion 130. In an aspect, body 112 extends in a longitudinal direction along a longitudinal axis 114.

Proximal portion 120 includes a proximal end 122 and a flange or lip 124. Proximal portion 120 is configured for removable attachment to pneumatic air hammer 150. For example, proximal portion 120 may be inserted into an opening (not shown) in an attachment collar 152 of pneumatic air hammer 150 and secured to pneumatic air hammer 150, e.g., using friction fit, snap fit, or any other manner of removable attachment. In some aspects, locking apparatus 110 may be removably attached to pneumatic air hammer 150 in a floating manner where, for example, locking apparatus 110 may be translatable relative to air hammer 150, e.g., along axis 114.

In some aspects, pneumatic air hammer 150 may include any medium barrel air hammer. In some aspects, for example, pneumatic air hammer 150 may be any type or size of air hammer or any other apparatus that is configured to drive locking apparatus 110 distally using air pressure or any other form of pressure or method of driving locking apparatus 110 distally, mechanical or otherwise. In some aspects, for example, pneumatic air hammer 150 may be configured to apply pressure at 70 PSI to locking apparatus 110.

With reference now to FIGS. 2-5, distal portion 130 of locking apparatus 110 extends distally from flange or lip 124 and includes a forming portion 132 and a guide portion 134.

Forming portion 132 includes a forming surface 136 that is configured to engage against a flange 612 (FIG. 6) of a duct sheet 602 (FIG. 6) to bend or form the flange 612 over an opening 606 of the duct sheet 602.

In some aspects, a portion of forming surface 136 may define an arcuate curvature. For example, as illustrated in FIG. 2, forming surface 136 may include a planar portion 136A and arcuate portions 136B and 136C extending from the planar portion 136A.

In some aspects, planar portion 136A may define a plane that is perpendicular to axis 114.

In some aspects, arcuate portions 136B and 136C may define arcs that curve proximally away from planar portion 136A. For example, each arcuate portion 136B and 136C may define a radius relative to a point on axis 122 that is proximal to planar portion 136A. Arcuate portions 136B and 136C may allow locking apparatus 110 to slide along a piece of sheet metal during forming of a seam.

Guide portion 134 includes a guide surface 138 that extends distally beyond forming surface 136 to a first end 138A. Guide surface 138 is configured to engage against a surface of a sheet metal panel 602 (FIG. 6) to guide locking apparatus 110 along sheet metal panel 602 (FIG. 6) while forming surface 136 bends a flange 612 (FIG. 6) of sheet metal panel 602 (FIG. 6) over a pocket 606 (FIG. 6) of sheet metal panel 602 (FIG. 6) as will be described in more detail below. In some aspects, guide surface 138 may be a planar surface and may define a plane orthogonal to the plane of planar surface 136A. In some aspects, distal portion 130 may define a fillet 140 (FIG. 3) between forming surface 136 and guide surface 138. For example, the fillet 140 may be between planar portion 136A, arcuate portions 136B and 136C, and guide surface 138 as illustrated in FIG. 3.

In some aspects, a width of each arcuate portion 136B and 136C may be greater than a width of planar portion 136A in a direction A (FIG. 2) that is perpendicular to axis 114 and parallel to guide surface 138. For example, the width of each arcuate portion 136B and 136C may be about twice the width of planar portion 136A in direction A (FIG. 2). For example, a width of planar portion 136A in direction A may be about 0.266 inches while a width of each arcuate portion 136B and 136C may be about 0.492 inches. Other relative widths between planar portion 136A and arcuate portions 136B and 136C may also be used.

In some aspects, locking apparatus 110 may be manufactured, for example, from A2 tool steel and hardened to inhibit ware during use.

In some aspects, locking apparatus 110 may be coated with an electro plate finish that may reduce wear and tear on the forming surface 136, guide surface 138, and any other surfaces of locking apparatus 110 during use. In some aspects, the finish may be black or any other color.

With reference now to FIGS. 6 and 7, a pair of sheet metal panels 602 and 610 are illustrated. Sheet metal panel 602 includes a portion 604 that is bent to form a pocket 606. A flange 112 extends from pocket 606 and is configured to be bent over pocket 606. Sheet metal panel 610 includes a flange 608 that is configured for insertion into pocket 606 of sheet metal panel 602. Once flange 608 is inserted into pocket 606, flange 612 may be bent over pocket 606 and flange 608 to secure flange 612 within pocket 606 such that flange 612 inhibits removal of flange 608 from pocket 606. This process forms a mechanical seam between sheet metal panels 602 and 612, sometimes called a Pittsburgh seam or a Pittsburgh lock.

With reference now to FIGS. 8-13, a method of forming a mechanical seam between two sheet metal panels is illustrated.

Referring initially to FIGS. 8 and 9, sheet metal plates 602 and 610 are positioned such that flange 608 is inserted into pocket 606. Locking apparatus 110 is attached to pneumatic air hammer 150 as described above. For example, locking apparatus 110 may be secured within an opening (not shown) of pneumatic air hammer 150 and translatable relative to air hammer 150 while removal of locking apparatus 110 from pneumatic air hammer 150 is inhibited, e.g., by flange 124.

As illustrated in FIGS. 8 and 9, locking apparatus 110 is positioned against the seam to be formed between sheet metal panels 602 and 608. For example, forming surface 136 of locking apparatus 110 may be positioned against flange 612 with guide surface 138 engaging against a surface 614 of sheet metal panel 602.

With locking apparatus 110 in position, a distal pressure may be applied to pneumatic air hammer 150, e.g., by a user, as illustrated, for example, in FIGS. 10 and 11 such that pneumatic air hammer 150 translates relative to locking apparatus 110 in the distal direction until the proximal portion 120 of locking apparatus 110 is fully received within the opening (not shown) of pneumatic air hammer 150. The distal pressure is then applied from pneumatic air hammer 150 to locking apparatus 110 such that locking apparatus 110 applies pressure against flange 612 of sheet metal panel 602.

With continued reference to FIGS. 10 and 11, pneumatic air hammer 150 is activated to drive locking apparatus 110 distally against flange 612, e.g., by depressing a trigger or other actuating mechanism. As locking apparatus 110 is driven distally against flange 612, flange 612 deforms against forming surface 136 to form a locking portion 616 (FIGS. 12 and 13) that inhibits removal of flange 608 from pocket 606. For example, forming surface 136 may bend locking portion over flange 608 and pocket 606 to form locking portion 616.

With reference now to FIGS. 12 and 13, while continuing to activate pneumatic air hammer 150, the user may slide or translate locking apparatus 110 along flange 612 to continue bending flange 612 over pocket 606 and flange 608 to form locking portion 616 along the entire length of flange 612. For example, the guide surface 138 of locking apparatus 110 may engage against surface 614 of the sheet metal panel 602 and guide locking apparatus 110 along the surface 614 as the locking apparatus 110 slides or translates along flange 612 during activation of pneumatic air hammer 150. As locking apparatus 110 slides or translates along flange 612, forming surface 136 engages flange 612 to form locking portion 616. In some aspects, arcuate portions 136B and 136C of forming surface 136 may facilitate the smooth sliding or translation of locking apparatus 110 along flange 612 while planar surface 136A engages flange 612 to form locking portion 616. In some aspects, arcuate portions 136B and 136C may also or alternatively be used to engage against flange 612 and form locking portion 616.

Once a sufficient length of flange 612 has been bent or formed into locking portion 616, the seam has been created and removal of the sheet metal panel 602 from the sheet metal panel 610 is mechanically inhibited, e.g., by a Pittsburgh style seam or lock. In some aspects, the sufficient length may be the entire length of flange 612. In some aspects, the sufficient length may be any desired length that inhibits removal of flange 608 from pocket 606, e.g., during normal use of the HVAC duct.

Although specific embodiments of the present invention have been described, it will be understood by those of skill in the art that there are other embodiments that are equivalent to the described embodiments. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiments, but only by the scope of the appended claims. 

What is claimed is:
 1. A locking apparatus for securing a first sheet metal panel to a second sheet metal panel, the locking apparatus comprising: an elongate body; a proximal portion extending proximally from the elongate body and configured for removable attachment to a pneumatic air hammer; a distal portion extending distally from the elongate body, the distal portion including: a forming surface that is configured to engage against a flange of the first sheet metal panel, the forming surface configured to bend the flange of the first sheet metal panel over a pocket of the first sheet metal panel when the pneumatic air hammer is activated to inhibit removal of a flange of the second sheet metal panel from the pocket; and a guide surface, the guide surface configured to engage against a surface of the first sheet metal panel to guide the forming surface along the flange of the first sheet metal panel.
 2. The locking apparatus of claim 1, wherein the forming surface includes an arcuate portion.
 3. The locking apparatus of claim 2, wherein the elongate body defines a longitudinal axis, the forming surface including a planar portion defining a plane perpendicular to the longitudinal axis, the arcuate portion extending from the planar portion.
 4. The locking apparatus of claim 3, wherein a width of the planar portion is less than a width of the arcuate portion in a direction perpendicular to the longitudinal axis and parallel to the guide surface.
 5. The locking apparatus of claim 3, wherein the arcuate portion curves proximally away from the planar portion, a radius of curvature of the arcuate portion being defined from a point on the longitudinal axis proximal of the planar portion.
 6. The locking apparatus of claim 1, wherein the guide surface extends distally beyond the forming surface.
 7. The locking apparatus of claim 1, wherein the guide surface is a planar surface.
 8. The locking apparatus of claim 7, wherein the guide surface is orthogonal to at least a portion of the forming surface and parallel to a longitudinal axis defined by the elongate body.
 9. The locking apparatus of claim 1, wherein a fillet is defined between the guide surface and at least a portion of the forming surface.
 10. The locking apparatus of claim 1, wherein the guide surface and the forming surface are integrally formed.
 11. A method for securing a first sheet metal panel to a second sheet metal panel, the method comprising: inserting a flange of the second sheet metal panel into a pocket of the first sheet metal panel; positioning a locking apparatus against the first sheet metal panel such that a forming surface of the locking apparatus engages against a flange of the first sheet metal panel and a guide surface of the locking apparatus engages against a surface of the first sheet metal panel; driving the locking apparatus against the first sheet metal panel such that the forming surface engages the flange of the first sheet metal panel and bends the flange of the first sheet metal panel over the flange of the second sheet metal panel, the bending of the flange of the first sheet metal panel over the flange of the second sheet metal panel inhibiting removal of the flange of the second sheet metal panel from the pocket.
 12. The method of claim 11, wherein driving the locking apparatus against the first sheet metal panel comprises sliding the locking apparatus along the flange of the first sheet metal panel from a first portion to a second portion of the flange, the sliding guided by the engagement of the guide surface against the surface of the first sheet metal panel, the second portion of the flange of the first sheet metal panel being bent as the locking apparatus slides along the flange from the first portion to the second portion of the flange of the first sheet metal panel.
 13. The method of claim 12, wherein the forming surface comprises at least one arcuate portion, the sliding of the locking apparatus comprising engaging the at least one arcuate portion against the second portion of the flange of the first sheet metal panel.
 14. The method of claim 11, wherein a proximal portion of the locking apparatus is configured for removable attachment to a pneumatic air hammer.
 15. The method of claim 14, wherein the locking apparatus is translatable relative to the pneumatic air hammer between a first position and a second position when removably attached to the pneumatic air hammer, the locking apparatus extending farther from the pneumatic air hammer when in the first positions than when in the second position, wherein positioning the locking apparatus against the first sheet metal panel comprises: positioning the locking apparatus against the flange of the first sheet metal panel with the locking apparatus in the first position; and translating the locking apparatus to at least the second position while positioned against the flange of the first sheet metal panel prior to driving the locking apparatus against the first sheet metal panel.
 16. The method of claim 14, wherein driving the locking apparatus against the first sheet metal panel comprises activating the pneumatic air hammer to drive the locking apparatus against the first sheet metal panel.
 17. The method of claim 11, wherein the guide surface is a planar surface.
 18. The method of claim 17, wherein the guide surface is orthogonal to at least a portion of the forming surface and parallel to a longitudinal axis defined by the locking apparatus.
 19. The method of claim 11, wherein a fillet is defined between the guide surface and at least a portion of the forming surface.
 20. The method of claim 11, wherein the guide surface and the forming surface are integrally formed. 